Composite metal manufacturing apparatus



March 10, 1953 R. E. KlNKx-:AD

COMPOSITE METAL MANUFACTURING APPARATUS 4 Sheets-Sheet l Filed Sept. 8, 1948 JNVENTOR.

March 10, 1953 R. E. KINKEAD 2,631,214

COMPOSITE METAL MANUFACTURING APPARATUS Filed Sept. 8, 1948 4 `Sheets-Sheet 2 1:: ISL- 36 Ci, 33 e3 @4 3 March 10, 1953 R. E. KINKE'AD 2,631,214

COMPOSITE METAL MANUFACTURING APPARATUS Filed Sept. 8, 1948 4 Sheets-Sheet 5 5 ArroR/vfys March 10, 1953 R. E.- KINKEAD I 2,631,214

COMPOSITE METAL MANUFACTURING APPARATUS WM5/wb@ 1.1.5 Y l INVENTOR.

Patented Mar. 10, 195,3

UNITED STATES PATENT oFF-ice VCOMPOSITE METAL MANUFACTURING APPARATUS .Robert l?.v .Kinkead Shaker Heights, Ohio, l. assignorto The Cleveland Trust Company, Cleve- ,land, hio, a corporation of` Ohio', as'trlste Application September 8, l1948, Serial No. 4 8,-182

(C1. ZlQf-LS) YV 13 Claims.

1 My invention relates to the manufacture` of composite metal,4 andis a continuation-in-part of my co-pendingf-application,.Serial No. 579,255, led February 2,2, 1945, now-abandoned, which application Wasa continuation-impart of my. apv plication Serial No. 40G-5695, filed August ql3,l941, now Patent No.- 2,4D,2 ,165, issued June 18, 1546. The processes disc1osed;;hereinand;in the said parent applications Aare claimedfin my co-pending application Serial.No.r2l0,924,led Augustl 8, 1951, which is a continuati'onfinfpart of the`I instant applicationand ot-my said application vSerial No. 579,255,5n1ed February 22, 1945,

An objectI of my. invention is to vprovide `improved methods and apparatus f or cladding, and

.especially for applyingaflayerof metal to -another by electric arcffusion YAnother object is to provide arrangements-for. manufacturing comrout eXcessiVedissipation of 4energy therein.

Another object isgto distribute the electric currenty in predetermined Aproportion to a plurality of simultaneously operating cladding. electrodes, and to controltherelative-current ksupplied to the electrodesjfor balancing heating and cooling eflects between the center and edges Aof a slab having a 'pluralityof self-,consuming electrodes laid thereon.

Still anotherobject is tov provide ,arrangements for applying a ,metallic coatingciuniform thickness, mechanical properties; and composition, With or Without fan vintermediate layer of alloying elements, and-which isfree'frrom blow holes, contamination with the air, irregularities in mechanical vstructureor hardness, weaknesses or other defects.

Other and further objects, features and advantages of the invention will become apparent Aas the description proceeds.

In carrying gouts the invention in vaccordance With a preferred v embodiment thereof, composite metal is producedxby Ydepositing*one ormore layers of claddingtmetalupon afslabV ofl'base metal. This is accomplished*byfarranging ag-roW-of selfconsuming electrodes@side-:byfside in l 'parallelA in a generally horizontal positionuponI the surface of a slab 'of metal.':xTheielectrodes lare in rod form,l or they mayfbe inixth uOrm: of relatively wide nat bars, andmayf e coated. withinsulatns ..materialfputzpreferablyheyfarebareand .af-,layer of fusiblednsulating material tvis placed between lthe electrodesrfand theslab surface. For protectiD-stile arcs which areto beproduced between ,the .electrodes,andtheslab, theelectrodes are covered-With slagiorming ymaterial in granular. or

gravelfflorm. Either the insulating material or vthe slag y forming material V4contains ionizing `substances for maintaining the arc.

f Electricalconnections are made in each of the electrodes and usually to the slab lfor supplying 4electric current and sustaining4 the arc which is struck A at the ends oi v` each electrode. As the electrode vis consumed, thefmetalof which j it is composed` is.V melted .and 'deposits upon the .sur-

face oitheslabfto form ametallic coating.

A betterwunderstanding of ithe invention .will

be afforded 'bythe' foi'ifn'mg detailed description considered in conjunctionl with the accompanyingr drawings, and thescope ofthe invention will beset forth in the claimsYv appended hereto.

in theA drawings:

Figure 1 .is a perspective view, .partially .schev y. rnatid of an arrangement l forv producing com- Yfposlde,frnetal, illustrating theprincplefof operation oi an enibodimentqofniy invention.

Figure Zisa side elevation-partially in section,

illustrating y composite metal ,manufacturing y'apparatus 'constituting "an )embodiment of. my invention.

'Figure-Sis a crosssectionalview. of the portion ofthe apparatus Vof Figurey 2, represented as cut by a vbroken plane 43-r3.

. VFigure `4 is acrossfsectional View of .theportion cof. the, apparatus of Figure zlfrepresented'as'rcut .by a plane :4v-i4.

vFigure. 5 is a .correspondingly AV*fragmentary Figure Gis acircuit'diagram illustrating-electrical connections for the apparatus .of 'Figures Figure 7 islanend-elevationuoi another embodiment of my' invention.

tional yiew, taken,on an.enlarg ed scale, on the en@ efe-Orf. Figuren.

vFieurefl is afragmeetaryrcrqssfsectional View `taken-on the line l iL-l Gg of `Figure 9.

Figure 1i is aperspective-yiew cian exemplary 5 slab clamp.

.Figure12 is aA vertical lcfoss-sectional View Figure 15 is a diagrammaticperspective.yiew

3 showing how the contacter bars of `Figures '7 to 13 are connected.

Like reference characters are utilized throughout the drawings to designate like parts.

My said co-pending application is itself a continuation-in-part of my application Serial No. 406,695, filed August 13, 1941, which has now matured into Patent No. 2,402,165, dated June 18, 1946. In said patent I have described and claimed certain arrangements for Welding by the use of self-consuming electrodes.

In Figure 1 of my present application I have illustrated an arrangement for the application of the present invention t the making of composite metal. It is frequently desired to deposit a layer of metal of one composition on the surface of metal of a different composition. For

example, stainless steel is deposited by electric arc fusion on a slab of ordinary low carbon steel prior to rolling so that after the slab has been rolled the resultant plate, sheet, or strip consists of a body of loW carbon steel with a stainless steel surface.

This may be accomplished With the present invention by laying a series of electrodes I3 along the surface of a slab or the like Il). Preferably in the arrangement of Figure l, the electrodes are provided with coatings I5 for forming a gaseous shield about the arcs although gaseous shielding material may be supplied to the arcs in other Ways. The series of electrodes are then covered with ux '26 for coniining the arcs by a slag shield and fused simultaneously depositing a layer of the electrode metal on the surface of the slab I0. The arcs are started at the ends of the electrodes I3 by wads of steel Wool, lings or the like interposed between bared ends of the electrodes and the slab Iii or by carbon pencils. Each arc then progresses along the electrode as the electrode is consumed,

It is also feasible, in order to reduce the expense of the electrodes, to employ electrodes I3 of relatively cheap material, and add the alloying elements separately. For example, a layer I5 of ferrochrome and metallic nickel particles or the like may be spread upon the surface of the slab Il) before arranging the electrodes iii thereon. The chromium, nickel or other alloying ingredients may be spread uniformly along the surface and ordinary steel electrodes I3 of a diameter to supply the desired amount of steel arranged thereon. The action of the arcs fuses the surface of the parent metal I0, the layer of alloying ingredients i6, and the metal of the electrodes themselves and allows the same to rniX and alloy to form a uniform alloy layer of the desired composition and thickness.

In this application of the process it is preferred to connect one side of an electrical current circuit to each electrode I3 With the other side connected to the slab lil. This may be accomplished by providing a separate motor-generator for each electrode, or, when it is desired to use alternating current, a transformer may be provided for each electrode. As shown in Figure l, transformers II may be connected to the three circuits of a three-phase system supplied by line wires I3, I9 and 23, so that each circuit supplies every third electrode through a transformer. In this Way the load is balanced on the supply lines, and at the same time the heat developed by the arcs is balanced through each group of three electrodes, providing a steadier and more uniform heating of the slab Iii and the layer of alloying material I6.

The slag or flux shield Which covers and con-l fines the arcs may be a prefused non-gas-forming material. An excellent slag for cladding with stainless steel and similar metal comprises crushed finishing slag from an electric arc furnace. However, other materials which are prefused and which do not give oi gas under the conditions attendant upon the cladding operation, may be used. Other materials, such as silica gravel, may also be employed. For cladding with materials or under conditions where the molten metal is not deleteriously affected by gas absorption, unprepared slags, which include limestone or other materials which give off non-oxidizing gases when melted, may be used.

The desired relation between the arc length, the rate of movement of the arc along the slab, and the rate at which electrode metal is added to the deposited metal, is obtained automatically with this process, eliminating the necessity of the nice correlation of these factors characteristie, for example, of hand and machine welding processes, The thickness of the coating I5 accurately and uniformly fixes the arc length, and the progression of the arc and the amount of electrode metal deposited are determined by the size of the electrode and the current density. Since each inch of Weld is made by an inch of electrode, an electrode is selected having a cross-sectional area equal to the desired crosssectional area of added metal in the Weld, allowance being made as usual for the elements lost in the are, I have used current densities of about 5,000 amp-eres per square inch of electrede to deposit the electrode on to the slab With a rate of arc travel of about l foot per minute, Higher current densities may be used to increase the rate of deposition.

Where the electrical connections are such as to permit a passage of current directly from one electrode to another, the electrodes are preferably spaced apart a sufcient distance to prevent such arcing across so that each arc passes between its electrode and the slab itself. The electrodes are kept sufficiently close to each other, however, so that the pools of the arcs run together so that the arcs travel at the same speed and a uniform penetration and coating composition is obtained across the entire surface of the slab.

The cooling of the fused metal is retarded by the protective arch formed over the deposit by the flux which has been melted by the heat of the arc, resulting in a substantial decrease in hardness where alloy steel is being deposited. When desired, an excess of flux may be employed to partially insulate the molten layer of flux from the atmosphere and further retard the cooling. An excess of flux may also be used to conceal the arc from view so as to blackout the cladding operation from enemy observation.

From the apparatus standpoint, there are a number of Ways in which my processes may be carried out, and I have illustrated herein by Way of example two diiferent apparatuses. These apparatuses are quite different in appearance and yet they operate fundamentally in the same way. The primary difference between these apparatuses is that in the apparatus of Figures 2 to 5 inclusive, a moving contact is established between the current source and the electrodes (i. e. the contact is moved along the electrodes in advance of the arc as the latter progresses), and

the ilux covering. is applied in thej saine way as the areV progresses, whereas in the apparatus of. Figures 'I to 15 inclusive, the entire slab and electrode assembly is covered with flux, and a series of contactors are provided along the length of the slab and these are. raised in sequence as the arc approaches them. The apparatus of Figures 2 to 5 inclusive will first be described.

Figure 3 illustrates an arrangementwhich has been found to be satisfactory in carryingout this process with the use of bare, instead of: coated, electrodes. In this arrangement. a bare electrode 2,1 is laid upon the slab and held spaced therefrom by a layer of insulating material 28. In one embodiment, this may be va strip composedrof thev material ordinarily used for the coatingV lon the covered electrodes, interposed between the elec trode and the slab 24. Thel strip 2t is made of a uniform thickness to space the electrodes the desired distance from the slab 24; andv of sufficient width to preventA the electrode from contacting the slab and shorting the electric circuit. The strip of material 2B, like a conventional coatingV for weldrcds, may consist of paper, wood flour, or other cellulosic material impregnated with sodium silicate, calcium oxide and magnesium oxide, or other slag forming and ionizing elements. If desired the silicates or otherv ele-v ments usually present in the electrode coatings which produce a fluxingv slag may be omitted from the coating {V-.or the strip 28, since the arc is completely Y shield-ed and the deposited metal is protected as. it coolsV by the slagrcoating provided by fusing of the flux 25 (Figure 2). ./-llternatively, the electrodes may be spaced and insulatedfrom the slab4 by a layer or strip of the sa., e material used as an over flux, or any similaifusible insulatingY and fluxing material.

The. secondary Windingsof the transformersy H are preferably Y connected, having what amountsto a grounded neutral connection since the base plate or slab llllis in, eect grounded as represented schematically by aground connection I4. However, as shown-each of the second arywindings is preferably connectedatone end directly to the slab IB in Yorder thatsuillcient current may eicientlyvbe supplied to the-electrodes.

`Iii-the arrangement of `Figure l, the` slab i3 is relativelyA narrow and a largef number ot relatifiieiy short 'electrodesv i3 are v laid; Side-br-Sicle across, the plateor slab l0. However,A myinven-- tionv is not limited to. thepspeciflc arrangement illustratedv in Figure l. For example, as illus,- trated in Figures 2 and-3, electrodes, inthiscase represented bybare electrodes'i, may also be laid lengthwise of a, relatively long slaby 2d. in thisV manner, few electrodes-need be handled, and the process and operations may more readily be carried out mechanically.l

KIn l'the arrangement of Figure 2 the slag-` forming ilux is fed to theslabl 24, as. tile-folli' 0fl arcs progresses from one end of the,slabtofthe other. n order to` avoid -dissipationfotenergy in the vportion of the electrode awayI fromn the, arc, andto avoid premature, destruction ofthe strip 28 byheating any part ci the ,electrode ex-V cept Vthat adjacent theV arc, means are provided for progressively moving the point of,l application oflelerctrical current to the,el ectrode,.asthel arcv progresses.V

rThe apparatus of Figures 2,;and3 comprises a suitable platform 3 l; carrying a .plurality` of Arota-tablerollers orvvheels32 for supporting, a slab-24 Whibhfisla be 90ste@ igiene.: acommsite metal slab. A' plurality of' conductors. 33; eachv termi#v hating-in acontact shoe 34- is'provided for supplying electrical current to the electrodes 2l, and a movable hopper 35 is provided for supplying the flux 26. tothe arcing electrodes and. covering the arcs.

For movably supporting the hopper 35, suitable means areprovided such-asia pair of rails 33 mounted oneither side of the platform 3l, a pair of main supporting Wheels 3l carried by the hopper 35, and a; pair ofv` guide wheels or balancewheels. 31', also4 carried bythe hopper 35, the wheels 3l and 31"' being adapted to roll upon the rails 33. For moving the hopper 35 and withdrawing the1contact-.-shoes` 34; as` the arcs progress, a series of racks.38 is provided, each mechanically securedto one ofthecontact rods or conductors 33, and each having a driving pinion 33 enrneshed therewith; The pinions 3.5

arev keyed to a commonadrive'shaft'M poweredl by a suitablemeanssuch asl-anV electric motor (not shown). For separately; feeding electrical power to each of the'conductor rods 33, separate insulated stationary contacts or shoesV 43 are provided, each of which, in turn, isiconnected to one of the branch cigrcuitsn44 of the. secondary side of the supply transformarsi? represented in Figure 6. It is to beunderstoodvthat vthe ground or neutral connection ,45 of the. secondary wind ings of the transformcrsgisgin practice directly connected to the slab24 through high conductivity contacting means-v (not'fshovvn).

A table 43 is provided for supporting the contacts 43 and other associated; apparatus including the conductors 33 and theracks 38.,

The hopper 35V is provided with an elongated spout 4l' extendinggtransversely acrossthe slab 24 for delivering the slag-forming'material 26 to.

the slab 24. As'illustrated'moreclearly in Figure.

3, the hopper 35 -has formedgtherein or'secured thereto a housing or casing 48 'having` a pluralityy of chambers 49 therein. fonpositioning the contact shoes 34. Each such contact shoe Sllfhas an upwardly extending locating` rod 5i secured to the shoe 34 and has a-suitable insulating mechanical. connection-such as-ablock of insulating material 52. For resilientlyl biasing the Contact shoe 34. downward to givethe requisite degree of contact pressure between the electrode 21 and the shoe 34, suitable means such as compression springs 53 are provided.

Each of the contact shoes-Mis electrically connected to therend of the corresponding conductor rod 33, as well aswbeing .mechanically connected thereto. Each of, the racks 38 is also mechanically connected. to the corresponding conductor rod 33, and iswinsulated; therefrom; For example, as illustrated, theupper surface of each rod 33 may be grooved to receive the rack 38 and a layerof suitable insulating sheet ma-. terial 54 is interposed ;,betweeny theflrack and the conductor rod. Suitable mechanicalv connecting meanssuch as insulated Vscrew-s or the.

like (not shown) are Dlov-idedffor effecting a rigid mechanical connection betweengtherack-B and the conductor rod 33.

The hopper35 is mechanicallywconnected to the contact shoesSIl,` althoughfinsulated therefrom for the purpose: of causing the hopperA 33 to be rolled along the; rail 36ers therack 38 is retracted to retract vthecontact shoes,v 34. This; mechanical connectionfbetween the4 contact shoev 34 and-the hopper 35,1is effected bythe. fitting of the insulated rod 5Il of :each,;,shoex34 within the rack housing 481. Preferably;V the :lower :side

of each conductor rod 33 is cut away to form a cylindrical segmental slot 55 iitting the top surface of the electrode 21, which prevents electrical Contact except at the shoes .34.

For locating the slab 24 and holding it in a iixed position as the cladding operation is being performed thereon, an end stop is provided for the slab 24. Preferably the table 46 is arranged to serve as the end stop. Insulation of the slab 24 from the table 46 is preferably effected by providing a suitable insulating insert 55 for the end of the table composed f slag, asbestos board, or other refractory insulating material. For similarly locating` the electrodes 21 and preventing movement thereof during the cladding operation, an end stop 51 is secured to the surface of the table 43. The stop 51 may take the form of a strip of insulating material such as a phenolic condensation product or fabric impregnated with plastic insulating material extending transversely across the table 46. Preferably, the ends 58 of the electrodes 21 overhang the slab 24 sufciently to permit the contact shoes 34 to be moved beyond the ends of the slab 24 in order that the arcs may continue from one end of the slab to the other, in order that the entire top surface of the slab may be coated.

Suitable means are provided for securing the contact shoes 43 in a fixed position on the table 46 and insulating them from the table 45. For example, they may be laid in troughs composed of insulating material 59 and secured by means of terminal studs I extending downwardly through suitable openings in the table 46, and insulated by means of insulating bushings 62.

vFor supporting the racks 33 and the conductor rods 33 as they are retracted along the slab 24, a series of suitable rollers 63 01 the like shown in Figure 5 may be provided, each consisting of a portion of a spherical roll, being composed of suitable insulating material and being mounted upon a rotatably-mounted shaft 54.

In order that the current in each electrode 21 may be maintained constant without interaction or" the current in one arc upon that of another, each terminal stud 3l preferably has a, separate electrical connection 55 thereto. A single set or" transformers l1 may be utilized for supplying the conductors or connections 65, but preferably branch circuits are formed by means of impedance isolation of each connection 65. Thus, suitable impedance devices such as chokecoils 56 may be interposed in series with each connection 65. For equally loading the phases of the transformers Il' successive choke-coils 65 are connected to diiierent transformers, each third choke-coil being connected to the same transformer out-put line.

For enabling individual adjustment of current in each arc, the choke-coils 56 are preferably adjustable, for example having adjustable taps 51. It is to be understood that for simplicity in the drawing.Y some of the connections and choke-coils have been omitted in Figure 6. Likewise in Figure 3 the middle portion of the apparatus is broken away.

My invention is not limited to the use of any particular dimensions. However, I have found that when a 4.-.inch slab approximately 30 inches wide by 18 feet long is to be coated, successful results may be obtained by utilizing electrodes laid side-by-side and connected in 15 different branch circuits through 15 choke-coils. Owing to the fact that the electrodes at the two sides or edges' of the slab 24 are subjected to a 8 greater cooling effect, and do not receive heating from lboth sides, I prefer to provide means for supplying additional heat to the side electrodes as by increasing the electrical power to them. For example, this may be accomplished by supplying additional current by setting the chokecoil 56 so as to have lower impedance than the remaining choke-coils $6.

In coating a 4-inch slab which is 30 inches wide and 18 feet long, satisfactory results may be obtained by utilizing 15 l-inch electrodes resting upon insulating strips T45 of an inch thick. In such arrangement with a current density of 3500 amps. per square inch, a burning speed of from 12 inches to 24 inches per minute of the electrode is obtained. The electrode has a composition such that when alloyed with the slab, it

will give a surfacecoating of the desired composition, taking into consideration that the dilution may be from 10% to 50%, depending upon the elements employed and the conditions of operation.

The insulating strip or layer may contain calcium fluoride or sodium fluoride as an ionizer for sustaining the arc. However, the invention is not limited to providing the ionizer in the electrode insulating material. This ionizing substance may also be provided in a prefused slagforming granular iiux.

In the course of the operation of the apparatus of Figures 2 and 3, the hopper 35 and the conductor rods 33, are moved to the right so that after a slab has been completely coated, the hopper 35 is entirely above the table 46. The completed slab is removed by sliding it to the left, and a fresh slab to be -coated is moved into place by inserting it from the left. Since the hopper 35 is still in p-osition completely to the right above the table 46, the top surface of the fresh clab to be coated is exposed. The rows of strips 28 of insulating material are then laid upon the slab 24, and the electrodes 21 are laid upon the strips 28 with the ends of each electrode resting against the insulating stop 51, and inserted under the contact shoe 34. If there is any flux remaining in the hopper 35, the spout 41 is closed by shutting a lower door (omitted from the drawing for the sake of simplicity). A temporary stop is clamped at the left-hand end of the slab -against the left ends of the electrodes 21 and the gear wheels 39 are rotated in the reverse direction to move the hopper 35 and the contact rods 33 Itoward the left-hand end of the slab 24. When the hopper 35 has reached a position about as far to the left as that shown in Figure 2, the rotation of the gears 39 is stopped, the clamps are moved from the left-v hand end of the rods 33. the hopper 35 is recharged with flux and the spout 41 is opened.

For enabling arcs to 'be started, lengths of wire may be wrapped around the ends of the electrodes 21 and laid in contact with the slab 24. After sufcient flux has been discharged to form the pile of slag-forming material 26 at the left-hand end of the slab 24 as shown in Figure 2, current is connected to the transformers l1 so as to start the arcs and thereupon power is applied to the drive shaft 4| for causing the hopper 35 to move to the right, and for causing the conductor rods 33 to be withdrawn gradually at approximately the same speed as the arc progresses along the slab 24. Additional slag-forming material is continuously discharged from the spout 31 of the hopper 35 as ii; moves to the right so that the arc is constantly protected vagainst spattering and kept stable in.po sition.

'Since the contact shoes V34-alvvaysremain relatively close to the arc, the `resistance .drop in the .electrode 2l' isrelatively small, vand only the end portion of the electrodebecomes heated so that the insulating material 23 is not destroyed until the arc approaches it. -Theportion of the electrode -21 between the contact shoe 3a and the terminal shoe 43 remains cool owing to the fact that no current ows vin this portion of the electrode. The presence of the -slag around the arc and the ionizing gases for maintaining the arc serve to protect the molten material from contamination from the atmosphere, `and prevent the spattering or blowingo-f the arcs soas 'to form 'blow-holes, and thus, :also Yaccomplish the freedom from irregularity and weakness. Owing to the uniformity with which the operation proceeds, a uniform coating is produced which is uniformrnot only as to thickness yand mechanical properties but also as to degree of alloying and chemical composition.

:As the rolling mechanism-approachesthe eX- treme Yright-hand position, the arcs reach the right hand end of the slab 24 and Vare thereupon confronted by the insulating block 55 which breaksthe electrical circuits between the velectrodes 2l andthe slab 24, lso-that the arcs are extinguished.

The vshort lengths of electrode 21 remaining under the contact shoes `34 are then removed, a completed composite 'instal slab 24 is rolled away tothe left, and the appara-tus is in condition for the coating of a fresh slab by repetition of the operations already described.

In carrying out the process with this apparatus, as in the embodiment illustrated in Figure 1, all of the arcs are started simultaneously'and progress together across the slab. The electrodes are kept sufficiently close to each other so that the pools of the varcs join forming in efie'ct a single pool in the form of a strip across the slab and moving uniformly throughout the length of the slab. The electrodes are preferably spaced, however, a suflicient amount to prevent aroing between the electrodes in the event the electrical connections are such as t0 permit such arcing. Because of the fact that eacharc is helped by the other arcs in the series, the penetration of the welds is uniform throughout the entire surface of the `slab resulting in a coating of uniform thickness and composition. The joining or .the pools also helps to keep all ofthe lar-cs moving at the same speed against :any tendency of .one arc to slow down or run ahead of the remaining arcs. In this way there is .no -'opportunity for the heat to run ahead of the arcs inthe slab to any substantial extent so that after the arcs have moved about an inch yor so along the slab the temperature of the slab in advance of the `arcs is uniform throughout 'the remainder of the length of the slab. Thus the penetration of the arcs is uniform throughout the entire length of the slab well as across its width, resulting in a high degree of uniform'- ity-of the `thickness and composition ofthe .coating.

In the embodiment of Figures 7 to 15 inclusive, I have shown a framework having a longitudinal opening therethrough, through which -a slab to be 'treated may be brought into the apparatus and removed from the apparatus. While the ends of the 'frame could be closed and -the slab inserted and removed laterally, :the

structure shown lends itself better -to .straight line production methods. Alvlou'ntedfor vertical movement at the top of the frame longitudinally thereof is a series of carriers for the contactor lbars which carry the cladding current to the electrodes. In the particular embodiment shown each carrier carries six contactors but this will be varied depending upon the number of electrodes. A lever mechanism is provided for each carrier so that as the `arc approaches a set of contactors its carrier may be raised out of the way. Current of course is then brought to the electrodes through the remaining contaetors, but it willbe clear that there is always a set of contactors fairly close to the arc, whereby heating up of the electrodes beyond the arc is avoided. In this particular embodiment I have shown square electrodes as distinguished from the rod-like electr-odes of thepreviously described embodiment, but of course rectangular or flat, broadvelectrodes may'also be used.

At the top of the frame there are shown six bus bars which are connected to the three phases oi`a source of -S-phase current with the iirst and fourth bus bars connected to phase A, the-second and-fifth to phase B, andthe third and sixth to phase C (see Figure 15).

As shown in Figures 7, 8 and l2 the apparatus according to -this embodiment comprises a base structure indicated generally at Hill from which rises the supporting corner mem-bers I9! connected by the cross-beams |62. 'The base structure lue is provided with leveling jacks |03 at its corners so that the slab Vsupport may be adiusted to any desired position. r*I'he slab is indicated at IM resting upon a lsupport m5. It may be clamped in position by the clamps indicated generally at H and shown in detail -in Figure 11. Such clamps may compriseia bolt l l2 and'nut I vI3 and the angle member i M having the tongue I i5. The base plate leila of the support is slotted as at H15 and the bolts H2 pass through the slots H6 and the tongues H5 enter into said slots. The nuts H3 are of suilicient size that they will not pass through the slots. In some instances it Will'not be necessary vto clamp the slab in position, and, as -a matter of fact, in some cases bolting the slab down may tend to cause cracking. VTherefore, the clamping means disclosed herein are for use in such cases where the clamping is found to be necessary or desirable.

Electrodes are indicated at Il and in the particular embodiment shown six such electrodes are placed side by side upon the slab and extending beyond the slab at one end as indicated at llia.

For conducting the current to the electrodes, i employ a plurality of contactor bars which in this instance are grouped in groups 4of six. By reference to Figures 8 and l0 it Will be clear that because of the relatively close spacing between the electrodes the contactor bars are disposed in a staggered condition in two l'rows of three. It will be understood, however, that if broader elec- .r trodes were used the contacter bars could be arranged in a single row Yand three contacter bars would suice.

rEhe electrodes shown are square in cross-'section and in actual practice I have used such electrodes which were 3/8" square. I have also used in practice broad electrodes which were 3A" thick and were 51/2 Wide. With lsuch electrodes a single row arrangement of oontactor bars is .perfectly feasible.

Each group of electrodes is mounted vin Va car- 11 rier comprising an inverted generally U-shaped member I8 provided with a pivot bolt 1 13. Pivoted on the bolt 1 |51 is the rod |21! and the lifting lever |21. Securely bolted to the end of the rod H20 is a weight |22.

A series of frame members, one for each carrier, are provided, each comprising the spaced upright members |213, 1230i, which are connected across the top by the members 124. The members |211 are provided with the bearing brackets 125 through which the rods 12d pass and which serve to maintain them in vertical alignment.

Each of the levers 12| is pivoted as at |25 between a pair of the members 123, 123e and its opposite end |21 extends between an opposite pair of members |23, 123e. Upward movement on the handle end 12'1 of a lever 121 raises that carrier and its contactor bars, which will be described hereinafter. Since the point 119 has arcuate movement about the pivot point 121i the slot |28 in the member 1|8 is elongated to avoid binding. A gravity latch |29 pivoted at 131i to the cross member |24 has the catch portion 13| (Figure 14) of the cam surface |32 whereby when the lever |21 is raised the latch |29 will swing to the right and then engage under the lever to hold it in its raised position.

Coming now to a description of the mounting of the contactor bars themselves, a block of insulating material 133 is secured by means of bolts |34 to each of the members |18. Bars 135 also bolted to the blocks |33 extend laterally and enter between the respective members 123 and $2311 on each side as indicated in broken lines at |36 in Figures '7 and 13. The members 136 thus ride between the members |23, |23a, which serve as guides therefor. The contactor bars themselves indicated at |31 are carried in pairs in the blocks |33. The electric cables from the bus bars are connected to the contactor bars by means of the clamping collars |38 which prevent the contactor bars from falling out through the holes in the block |33. A bracket |39 is secured to the member 118 as by riveting or the like at |40, and carries an insulating pad |41. As best seen in Figure 9, sleeves |42 are welded or otherwise suitably secured to the ends of the contactor bars to act as retainers for the compression springs 143. Thus when a carrier 1 18 is lowered onto the slab by disengaging the catch member |29, the weight |212 presses the C-shaped member downward and the force is transmitted through the bracket 139 and the springs 143 to the contactor bars, thus providing for the equalization of pressures, so that each individual contactor bar is brought into firm contact with its particu lar electrode. When a carrier is raised the springs |43 tend to force the contacter bars downwardly until the clamping collars 138 come to rest on the block 133.

I have shown six bus bars in Figure 7 indicating by the reference numerals |44. As shown in. Figure 15 these are connected to the B-phases of a S-phase source of power, and the bus bars are connected to the contacter bars as clearly shown in Figure 15. The connecting cables have been omitted in the other figures for the sake of clarity. The bus bars are clamped between insulating plates 145, |46, which are supported upon the members |02.

By reference to Figure 8 it will be observed that one group of contacter bars contacts the electrodes beyond the end of the slab. This is in order to permit of cladding the slab all the Way 12 to its end while still having contact with the electrodes.

In practice the insulation is applied to the slab to be treated and the electrodes are then laid in place. The insulation preferably consists of a layer of granular ux such as crushed electric furnace finishing slag, or the like. The contactors are positioned on the electrodes and steel filings, or the like, are piled across the front end of each electrode for the purpose of starting the arc. The entire slab and the electrodes are then covered with granular ux which may be held in place by dams if desired. When the arcs are started by means of the steel iilings, or millings, they travel along the length of the slab as the cladding operation proceeds, and each succeeding set of contactors is raised as the arcs approach within a few inches of them by operating the appropriate lever |21. This method of contacting has the same effect as the rolling contact method described above in that it prevents cverheating of the cladding material and premature melting of the insulating flux by making it unnecessary for the heavy current to pass through more than a short-length of cladding material to reach the arcs.

While I have shown and particularly described herein certain embodiments of my invention and certain methods of operation embraced therein, by way of example, it will be clear to those skilled in the art that many modifications and variations are possible. It is my intention not to limit myself to the specific embodiments described except insofar as they are set forth in the claimswhich follow.

Having now fully described my invention, what I claim as new and desire to secure by Letters Patent is:

l. Apparatus for cladding a slab of metal comprising a support for a slab to be clad, a plurality of contactor carriers, a plurality of electrode con tactors supported by each carrier, means sus pending said carriers in longitudinally spaced re lationship along and above said slab support, said carrier suspending means including means for selectively shifting each carrier and associated contactors to an open circuit position, a source of welding current, electrical connections between said source of Welding current and said contactors, and other electrical connections to said current source and adapted to make electrical connection with a slab mounted on said slab support.

2. An apparatus for the purpose described, comprising a frame having an opening through which a slab tobe treated may be inserted, a support for a slab within said frame. a plurality of longitudinally spaced carriers suspended from said frame for vertical motion with respect thereto, means for selectively raising and lowering said carriers individually, a set of contactors resiliently mounted on each of said carriers, a set of bus bars disposed longitudinally of said frame at the top, and exible connections from said bus bars to the contactors in each of said sets.

3. An apparatus according to claim 2, in which each carrier carries six contactors, and in which there are six bus bars, the rst and fourth, the second and fifth, and the third and sixth of said bus bars being connected respectively to the three phases of a source of three-phase current.

4. An apparatus according to claim 2, in which said contactors are individually spring-mounted to equalize .their tentati pressure.

5. An apparatus according to claim 2, in which the means for raising and lowering said carriers comprises a linkage terminating in a lever eX- tending laterally from said frame, for each said carrier.

6. In an apparatus of the class described, havlng longitudinally spaced sets of contactor bars, each of said sets being actuated by a single element, means for producing substantially equal contact pressure on each bar of a set comprising an individual spring mounting for each contactor bar with relation to said element.

7. A cladding assembly comprising a slab to be cladded, a continuous layer of fusible insulating material lying on said slab, a plurality of elongated cladding electrodes of a relatively small volume with respect to the volume of said slab disposed side-by-side in spaced relation on said insulating material, said electrodes being arranged substantially parallel to each other and substantially parallel to the slab, each of said electrodes being adapted to be engaged by a series of contactors longitudinally thereof, and a layer of granular iiuxing material completely covering said electrodes and slab, for the purposes described.

8. An assembly according to claim 7, in which said iiuxing material is electric furnace nishing slag.

9. Apparatus for producing -a composite slab of i metal comprising means for supporting an assembly including a base slab of metal and a plurality of elongated electrodes with the upper surface of said assembly in a substantially horizontal plane, a plurality of electrical contacts arranged above said supporting means each of said contacts being adapted to engage and make electrical contact with a side surface of an electrode included in an assembly supported by said supporting means, means for supplying electrical current to said contactors and to a slab supported by said supporting means, and means for moving said contactors away from the arcing ends of electrodes included in an assembly carried by said supporting means as said electrodes are consumed.

10. Apparatus for producing a `composite slab of metal comprising means for supporting an assembly including a base slab of metal and a plurality of elongated metal electrodes disposed longitudinally thereabove with the upper surface of such assembly disposed in a substantially horizontal plane, a plurality of electrical contactors disposed above said supporting means and aligned in a transverse row, said contactors being adapted to engage and make electrical contact with side surfaces of electrodes included in an assembly carried by said support, means for supplying electrical current to said contactors and to a slab supported by said supporting means, and means for moving said contactors away from the arcing ends of electrodes included in an assembly carried by said supporting means as such electrodes are consumed.

11. Apparatus for producing a composite slab of metal comprising means for supporting an assembly including a base slab of metal and a plurality of elongated metal electrodes disposed longitudinally thereabove with the upper surface of such assembly disposed in a substantially horizontal plane, a plurality of electrical contactors disposed above said supporting means and aligned in a transverse row, said contactors being adapted to engage and make electrical contact with side surfaces of electrodes included in an assembly carried by said support, means for supplying electrical current to said contactors and to a slab supported by said supporting means, impedance means respectively connected in series with said contactors for electrical isolation of said contactors, those of said impedances connected to intermediate contactors having substantially the saine impedance, and those impedances connected to the end contactors having reduced values of impedance for supplying additional current to the end electrodes, and means for moving said contactors away from' the arcing ends of electrodes included in an assembly carried by said supporting means as such electrodes are consumed.

12. Apparatus for producing a composite slab of metal comprising means for supporting an assembly including a base slab of metal and a plurality of elongated metal electrodes disposed longitudinally thereabove with the upper surface of such assembly disposed in a substantially horizontal plane, a plurality of electrical contactors disposed above said supporting means and aligned in a transverse row, said contactors being adapted to engage and make electrical contact with side surfaces of electrodes included in an assembly carried by said support, a common current source for supplying current to said slab and to said contactors in parallel, means for causing the electrical power supplied to the end contactors in the row to be relatively greater than that supplied to intermediate contactors, and means for moving said contactors away from the arcing ends of electrodes included in an assembly carried by said supporting means as such electrodes are consumed.

13. Apparatus for producing a composite slab of metal comprising means for supporting an assembly including a base slab of metal and a plurality of elongated electrodes with the upper surface of said assembly in a substantially horizontal plane, a plurality of electrical contactors arranged above said supporting means each of said contactors being adapted to engage and make electrical contact with a side surface of an electrode included in an assembly supported by said supporting means near the arcing end of such electrode, means for supplying electrical current to said contactors and to a slab supported by said supporting means, a hopper with a discharge spout adapted to feed slag forming material, means for supporting said hopper above said slab support and means for relatively moving said hopper and said contactors with respect to an assembly carried by said supporting means in the direction of the length of the elongated electrodes included in such assembly and away from the arcing ends of such electrodes.

ROBERT E. KINKEAD.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 2,151,914 Hopkins Mar. 28, 1939 2,191,469 Hopkins Feb. 27, 1940 2,191,481 Hopkins Feb. 27, 1940 2,220,576 MacKusick Nov. 5, 1940 FOREIGN PATENTS Number Country Date 282,527 Great Britain Dec. 29, 1927 

